Apparatus for indexing and affixing components to a substrate

Abstract

An apparatus (400) used for indexing and affixing components to a substrate includes a vacuum conveyor and a controller (816) for controlling operation of the apparatus (400). The conveyor includes pallets (102), first and second tracks (414, 416), first and second motors (502, 503), a vacuum source, a plenum (110), and first and second elevators (404, 405). The pallets carry the substrate, while the first and second tracks guide the pallets. The first motor is used for driving a pallet in a first direction on the first track, while the second motor is used for driving a pallet in a direction opposite to the first direction on the second track. The plenum is coupled to the vacuum source and at least one pallet for applying adhering forces to the substrate. The first and second elevators are used for transferring a pallet between the first and second tracks.

What is claimed is: 
     
       1. An apparatus, comprising: a vacuum conveyor, comprising: a plurality of pallets for carrying a substrate;   first and second linearly slidable tracks for guiding the plurality of pallets, wherein the first linearly slidable track is positioned above the second linearly slidable track;   a first motor for linearly driving at least one of the plurality of pallets in a first direction on the first linearly slidable track;   a second motor for linearly driving at least one of the plurality of pallets in a direction opposite to the first direction on the second linearly slidable track;   a vacuum source;   a plenum coupled to the vacuum source and coupled to at least one of the plurality of pallets for applying adhering forces to the substrate;   first and second elevators coupled to the first and second linearly slidable tracks for transferring at least one of the plurality of pallets between the first and second linearly slidable tracks; and     a controller coupled to the vacuum conveyor to enable movement of the vacuum conveyor.   
     
     
       2. The apparatus as recited in claim 1, wherein the vacuum conveyor further comprises at least one sensor coupled to the controller for sensing linear positioning of at least one of the plurality of pallets while being guided by one of the first and second linearly slidable tracks. 
     
     
       3. The apparatus as recited in claim 1, wherein each of the first and second elevators further comprises a push-off mechanism activated by the controller and positioned at opposite ends of the first and second elevators for dispensing a pallet onto a corresponding one of the first and second linearly slidable tracks. 
     
     
       4. The apparatus as recited in claim 1, wherein each of the plurality of pallets further comprises at least one magnet for magnetically coupling a pallet carried by one of the first and second elevators to an adjacent pallet guided by a corresponding one of the first and second linearly slidable tracks. 
     
     
       5. The apparatus as recited in claim 1, wherein each of the first and second elevators further comprises a locking mechanism activated by the controller for limiting linear motion of a pallet being transferred between the first and second linearly slidable tracks. 
     
     
       6. The apparatus as recited in claim 1, wherein each of the first and second elevators comprises an air cylinder for transferring a pallet between the first and second linearly slidable tracks. 
     
     
       7. The apparatus as recited in claim 1, wherein each of the plurality of pallets is electrically coupled to an electrical source, and wherein each pallet is independently controlled by the controller for applying a controllable heat to a corresponding portion of the substrate carried by it. 
     
     
       8. The apparatus as recited in claim 7, wherein each of the plurality of pallets comprises: a pallet assembly comprising: a vacuum transfer plate having a first plurality of perforations for coupling to the substrate,   a heater plate having a second plurality of perforations for heating the vacuum transfer plate,   a carrier plate having at least one perforation coupled to the vacuum transfer plate and the heater plate;     a first end of each of a plurality of thermally insulated posts coupled to a bottom surface of the carrier plate; and   a transport plate, wherein a top surface of the transport plate is coupled to an end opposite to the first end of the plurality of thermally insulated posts for transporting the pallet assembly.   
     
     
       9. The apparatus as recited in claim 8, wherein the transport plate has a linear length that is longer than the linear length of the pallet assembly, thereby thermally isolating the plurality of pallets from each other while being guided by one of the first and second linearly slidable tracks. 
     
     
       10. The apparatus as recited in claim 8, wherein the first and second plurality of perforations are substantially aligned to each other. 
     
     
       11. The apparatus as recited in claim 8, wherein at least one thermally insulated post has a cavity extending throughout the at least one thermally insulated post, wherein the cavity of the at least one thermally insulated post is coupled to the at least one perforation and to the plenum for applying a vacuum to the pallet assembly. 
     
     
       12. The apparatus as recited in claim 8, wherein a bottom surface of the carrier plate comprises a plurality of fins for dissipating heat from the pallet assembly. 
     
     
       13. The apparatus as recited in claim 12, further comprising a fan for forcing air flow through the plurality of fins, thereby accelerating dissipation of heat from the pallet assembly. 
     
     
       14. The apparatus as recited in claim 7, wherein for at least one pallet, the vacuum conveyor further comprises an electrical coupling device coupled to the electrical source, wherein the electrical coupling device is used for electrically coupling to the at least one pallet, and for regulating its temperature by way of the controller. 
     
     
       15. The apparatus as recited in claim 7, wherein for at least one pallet, the vacuum conveyor further comprises a thermal sensor coupled to the controller for monitoring the temperature of the at least one pallet. 
     
     
       16. The apparatus as recited in claim 7, further comprising: a shroud having at least one opening for enclosing a substantial portion of the apparatus;   at least one hose coupled to at least one opening in the shroud for extracting fumes from chemical reactions occurring on a top surface of the substrate caused by heating of at least one of the plurality of pallets; and   at least one fan coupled to at least one opening in the shroud for cooling the top surface of the substrate carried by a corresponding one of the plurality of pallets.   
     
     
       17. A manufacturing line comprising the apparatus of claim 1 for indexing the substrate along the manufacturing line. 
     
     
       18. A manufacturing line comprising the apparatus of claim 7 for affixing components onto the substrate and for indexing the substrate along the manufacturing line. 
     
     
       19. An apparatus, comprising: a vacuum conveyor; and   a controller coupled to the vacuum conveyor to enable movement of the vacuum conveyor,   the vacuum conveyor, comprising: a plurality of pallets for carrying a substrate;   first and second linearly slidable tracks for guiding the plurality of pallets, wherein the first linearly slidable track is positioned above the second linearly slidable track;   at least one sensor coupled to the controller for sensing linear positioning of at least one of the plurality of pallets while being guided by one of the first and second linearly slidable tracks;   a first motor for linearly driving at least one of the plurality of pallets in a first direction on the first linearly slidable track;   a second motor for linearly driving at least one of the plurality of pallets in a direction opposite to the first direction on the second linearly slidable track;   a vacuum source;   a plenum coupled to the vacuum source and coupled to at least one of the plurality of pallets for applying adhering forces to the substrate; and   first and second elevators coupled to the first and second linearly slidable tracks for transferring at least one of the plurality of pallets between the first and second linearly slidable tracks, wherein each of the first and second elevators further comprises: a push-off mechanism activated by the controller and positioned at opposite ends of the first and second elevators for dispensing a pallet onto a corresponding one of the first and second linearly slidable tracks;   a locking mechanism activated by the controller for limiting linear motion of a pallet being transferred between the first and second linearly slidable tracks; and   an air cylinder for transferring a pallet between the first and second linearly slidable tracks; and     wherein each of the plurality of pallets further comprises at least one magnet for magnetically coupling a pallet carried by one of the first and second elevators to an adjacent pallet guided by a corresponding one of the first and second linearly slidable tracks.     
     
     
       20. A manufacturing line comprising the apparatus of claim 19 for indexing the substrate along the manufacturing line. 
     
     
       21. An apparatus, comprising: a vacuum conveyor; and   a controller coupled to the vacuum conveyor to enable movement of the vacuum conveyor;   the vacuum conveyor, comprising: a plurality of pallets for carrying a substrate;   at least one electrical coupling device coupled to an electrical source, wherein the at least one electrical coupling device is used for electrically coupling to at least one pallet, and for regulating its temperature by way of the controller; and   at least one thermal sensor coupled to the controller for monitoring the temperature of at least one pallet;   wherein each of the plurality of pallets comprises: a pallet assembly comprising: a vacuum transfer plate having a first plurality of perforations for coupling to the substrate;   a heater plate having a second plurality of perforations for heating the vacuum transfer plate, wherein the first and second plurality of perforations are substantially aligned to each other; and   a carrier plate having at least one perforation coupled to the vacuum transfer plate and the heater plate;     a first end of each of a plurality of thermally insulated posts coupled to a bottom surface of the carrier plate; and   a transport plate, wherein a top surface of the transport plate is coupled to an end opposite to the first end of the plurality of thermally insulated posts for transporting the pallet assembly;     first and second linearly slidable tracks for guiding the plurality of pallets, wherein the first linearly slidable track is positioned above the second linearly slidable track;   a first motor for linearly driving at least one of the plurality of pallets in a first direction on the first linearly slidable track;   a second motor for linearly driving at least one of the plurality of pallets in a direction opposite to the first direction on the second linearly slidable track;   a vacuum source;   a plenum coupled to the vacuum source and coupled to at least one of the plurality of pallets for applying adhering forces to the substrate;   first and second elevators coupled to the first and second linearly slidable tracks for transferring at least one of the plurality of pallets between the first and second linearly slidable tracks; and     a controller coupled to the vacuum conveyor to enable movement of the vacuum conveyor,   wherein at least one thermally insulated post has a cavity extending throughout the at least one thermally insulated post, and wherein the cavity of the at least one thermally insulated post is coupled to the at least one perforation and to the plenum for applying a vacuum to the pallet assembly, and   wherein the transport plate has a linear length that is longer than the linear length of the pallet assembly, thereby thermally isolating the plurality of pallets from each other while being guided by one of the first and second linearly slidable tracks.   
     
     
       22. A manufacturing line comprising the apparatus of claim 21 for affixing components onto the substrate and for indexing the substrate along the manufacturing line. 
     
     
       23. An apparatus, comprising: a vacuum conveyor, comprising: a plurality of pallets for carrying a plurality of substrates;   first and second linearly slidable tracks for guiding the plurality of pallets, wherein the first linearly slidable track is positioned above the second linearly slidable track;   a first motor for linearly driving at least one of the plurality of pallets in a first direction on the first linearly slidable track;   a second motor for linearly driving at least one of the plurality of pallets in a direction opposite to the first direction on the second linearly slidable track;   a vacuum source;   a plenum coupled to the vacuum source and coupled to at least one of the plurality of pallets for applying adhering forces to at least one of the plurality of substrates;   first and second elevators coupled to the first and second linearly slidable tracks for transferring at least one of the plurality of pallets between the first and second linearly slidable tracks; and     a controller coupled to the vacuum conveyor to enable movement of the vacuum conveyor.